Method of manufacturing a tubular storage assembly

ABSTRACT

A tubular storage assembly and method of making the same is disclosed. The present invention provides a tubular storage assembly that has an outer shell of heavy weight material such as an un-cut leather hide. The outer shell material is formed into the desired shape having two opposite edges that are configured to mate in the finished assembly. A zipper or other suitable fastening system is stitched onto the opposite edges while the shell material is flat. The mating edges are drawn together and the fastening system engages to retain the shell in the tubular formation. Finally the fasteners are concealed by permanently adhering a cover strip over the fastening system. As can be seen in this manner the formation of a fully stitched tubular storage assembly is provided that overcomes the de-lamination problems often encountered in the prior art.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims priority from earlier filedU.S. Provisional Patent Application No. 60/520,092, filed Nov. 14, 2003,the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to a new method of constructinga tubular assembly. More specifically, the present invention relates toa method of manufacturing and assembling a tubular storage assemblyusing heavy gauge cladding material, such as leather material from afull weight, un-cut hide.

Typically, tubular storage assemblies are desirable for containing,protecting and transporting large format blueprints or artwork in arolled fashion. As can be appreciated, this type of storage device isparticularly desirable to architects, engineers, interior designers orartists who must frequently transport presentation materials to and fromstudios, clients' offices or project sites. In order for this type ofstorage tube to be effective in protecting its contents, the tube musthave relatively rigid side walls and have a relatively high level ofweather resistance. Typically, the materials used to achieve thisobjective have been molded or extruded plastics. While theses plastictubes have been effective in providing the necessary protection, mostusers consider them to be quite unattractive. Generally the function ofthe assembly has always taken precedence over the exterior appearanceresulting in a product that is formed from a cheap injection moldedplastic or a light weight stitched material.

Alternatively, some tubes in an attempt to appeal to the desire of theuser to present a better image have been provided with an exteriorfabric or leather shell to improve their appearance. The difficulty inthe prior art is that in order to form a tube, the materials must belight weight. This is necessary to allow the materials to be stitchedand then inverted to hide the hems. For example, in order for amanufacturer to utilize a fabric or soft leather shell, the shell mustbe first stitched from the rear side of the shell in an inverted mannerand then reversed. Since the material is pliable to allow inversion ithas no structural integrity of its own. Accordingly, an insert such as aplastic tube must be then added to provide the necessary rigidity toallow the tube to be used to protect the documents stored therein. Thedrawback to this construction is that the shell material is relativelythin and is subject to rapid wear and failure.

Another solution provided in the prior art is to adhere a heaviermaterial directly to the outer surface of the tube insert. When thematerial is adhered to the insert by utilizing this method a heaviermaterial can be utilized for formation of the shell. In this casehowever, the seams are not stitched to one another, they are simplyglued onto the plastic insert. Due to the nature of this construction,durability of the finished product is rather low. The adjacent edges ofthe shell material begin to release from the insert quickly therebydetracting from the appearance of the device.

Accordingly, there is a need for a tubular storage assembly thatutilizes a heavy weight outer shell. There is a further need for atubular storage assembly that is durable and maintains an attractiveappearance throughout the entire life of the device. Further there is aneed for a process that facilitates the manufacture and assembly oftubular assemblies that utilize heavy weight shell materials.

BRIEF SUMMARY OF THE INVENTION

In this regard, the present invention provides a tubular storageassembly that is manufactured in a novel manner that allows the use of aheavy weight shell material. The shell material it self is quite durableand is fashioned in such a manner utilizing the method of the presentinvention in order to produce a structure that facilitates themaintenance of its tubular shape and relation throughout the life of theproduct without the de-lamination issues encountered in the prior art.

In the process of the present invention, a sheet of heavy weight shellmaterial is provided. The material is preferably a full weight leatherhide although other materials such as a heavy canvas, a denim or anyother suitable material are also anticipated under the presentdisclosure. The sheet is formed into the desired shape to create theouter wall of the tube. Typically this forming step would involvestamping or cutting of the sheet material. Two opposing edges of thesheet are cut to form a matching edge seam. A two part linear fastenersuch as a zipper, hook and loop, a row of buttons, or any other suitablesystem is then attached wherein one half of the system is attached toone side of the seam and the other half of the system is attached to thesecond opposing side of the seam. The shell is then rolled into atubular shape by bringing the opposing sides of the seam together andconnecting the fasteners provided thereon. The seam is then covered bypermanently adhering a cover strip over the seam to conceal the linearfastener system and give the tube a uniform appearance. End caps canthen be added either by stitching or by using a slide on type cap.Finally, a plastic tube or another liner material may be included toenhance the rigidity of the tube walls and provide a low frictionsurface to facilitate the insertion or withdrawal of documents storedtherein.

It can be appreciated that a distinct advantage provided by the presentinvention is that the fastener system can be stitched into the shellwall while the wall is flat. This is a great improvement whereinstitching of a tubular assembly is nearly impossible when usingrelatively rigid materials.

Accordingly, it is an object of the present invention to provide a novelconstruction for a tubular storage assembly. It is a further object ofthe present invention to provide a novel construction for a tubularstorage assembly that includes an outer shell that is formed from adurable heavyweight material. It is yet a further object of the presentinvention to provide a tubular storage assembly and a method ofmanufacturing the same that provides for a heavyweight exterior shellthat is easily fabricated and assembled while being resistant tode-lamination during usage.

These together with other objects of the invention, along with variousfeatures of novelty which characterize the invention, are pointed outwith particularity in the claims annexed hereto and forming a part ofthis disclosure. For a better understanding of the invention, itsoperating advantages and the specific objects attained by its uses,reference should be had to the accompanying drawings and descriptivematter in which there is illustrated a preferred embodiment of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings which illustrate the best mode presently contemplatedfor carrying out the present invention:

FIG. 1 is a front perspective view of a tubular storage assembly of thepresent invention;

FIG. 2 is a side view of the tubular storage assembly of the presentinvention;

FIG. 2 a is a cross sectional view of the tubular storage assembly takenalong line A-A of FIG. 2;

FIG. 3 a is a perspective view of the tubular storage assembly of thepresent invention with the handle in a first alternate position; and

FIG. 3 b is a perspective view of the tubular storage assembly of thepresent invention with the handle in a second alternate position.

DETAILED DESCRIPTION OF THE INVENTION

Now referring to the drawings, the tubular storage assembly is shown andgenerally illustrated in the figures. As can be seen the assembly 10principally includes an outer shell member 12, top and bottom end caps14, 16 and a transport handle 18. As will be further described below,the storage assembly 10 may also include an inner support tube 20 thatprovides additional ridgity to the assembly 10 while also providing asmooth inner surface to facilitate insertion and removal of rolleddrawings and such.

Turning to FIG. 1, the storage assembly 10 can be seen to besubstantially tubular. While the assembly 10 is shown as a cylindricaltube, clearly any tubular configuration such as octagonal, hexagonal,square, etc would also fall within the disclosure of the presentinvention. The general concept is directed to providing a tubularstorage assembly 10 and a method of making the same that utilizes aheavy weight outer shell material 12 and accordingly the exact shape ofthe finished outer geometry is not a critical or limiting factor butsimply a design choice. Further, the tubular assembly 10 is shown toinclude a fixed end cap 16 on one end and a removable cap 14 on theother. While the tubular assembly 10 requires at least one end cap 14 tobe removable, clearly both ends 14, 16 could be provided as removable ifdesired. Similarly, while a particular handle 18 configuration is shown,this is primarily a design choice. A different handle 18 may besubstituted into the present disclosure without deviating from thegeneral concept which is directed towards the formation of the tubularassembly 10 utilizing a heavy weight outer shell 12 material.

In this regard, turning now to FIGS. 2 and 2 a, the present inventionprovides, as was summarily stated above, a tubular storage assembly 10that is manufactured in a novel manner that allows the use of a heavyweight outer shell 12 material. It is important to the present inventionthat the shell material 12 is provided as a highly durable material. Thematerial is preferably a full weight leather hide although othermaterials such as a heavy canvas, a denim or any other suitable materialare also anticipated under the present disclosure. The use of suchmaterials allows the storage assembly 10 to be fabricated to includestylish and attractive elements while having a distinguished andprofessional appearance. Further, the rigidity of the material 12 itselfallows fabrication of an assembly 10 utilizing the method of the presentinvention in order to produce a structure that facilitates themaintenance of its tubular shape and relation throughout the life of theproduct without the de-lamination issues encountered in the prior art.

In the process of the present invention, a sheet of heavy weight outershell material 12 is provided. The sheet 12 is formed into the desiredshape to create the outer wall of the tube. Typically, this forming stepwould involve stamping or cutting of the sheet material 12. Two opposingedges 22, 24 of the sheet are cut to form a matching edge seam. A twopart fastening system 26 such as a zipper, hook and loop, a row ofbuttons, or any other suitable system is then attached wherein one halfof the fastening system 26 is attached to one side 22 of the seam andthe other half of the fastening system 26 is attached to the secondopposing side 24 of the seam. The shell 12 is then rolled into a tubularshape by bringing the opposing sides 22, 24 of the seam together andconnecting the fastening system 26 provided thereon. By first attachinga mechanical fastening system 26 onto the edges 22, 24 while the shell12 is flat, conventional techniques can be utilized to secure themechanical fastening system 26 to the edges 22, 24 of the outer shell 12material. For example, mating halves of a zipper can be separated andsimply sewn onto the edges of the outer shell material 12. In contrast,once the outer shell 12 is rolled into a tube it is virtually impossibleto stitch the material to a fastening system 26. Further due to theresilient nature of the shell material 12, it would be difficult to holdthe shell 12 in the rolled position for further stitching. With lighterweight materials, this can be done by sewing the fastener and thematerial from the reverse and inverting the tube after the sewing iscompleted. The problem is that with the heavy weight outer shell 12material of the present invention, inversion is impossible. Once thefastening system 26 is attached to outer shell material 12, the matingedges 22, 24 are drawn together and maintained in place by engaging theopposing sides of the fastening system 26. The seam is then covered bypermanently adhering a cover strip 28 over the seam to conceal thefastener system 26 thereby giving the exterior of the tube 10 a uniformappearance.

End caps 14, 16 can then be added once the assembly 10 is positionedinto its tubular shape. As stated above, a permanent end cap 16 can beinstalled by stitching the cap 16 onto the desired end of the storageassembly 10. Similarly, as stated above, at least one end cap 14 isprovided as a slide on type cap 14 thereby allowing access into thetubular assembly 10 for insertion or removal of stored materials.Finally, a plastic tube 20 or another liner material may be included toenhance the rigidity of the tubular assembly 10 walls and provide a lowfriction surface to facilitate the insertion or withdrawal of documentsstored therein.

It can be appreciated that a distinct advantage provided by the presentinvention is that the fastener system 26 can be stitched into the shellwall 12 while the wall 12 is flat. This is a great improvement whereinstitching of a tubular assembly is nearly impossible when usingrelatively rigid materials.

Turning now to FIGS. 3 a and 3 b, another novel feature of the presentinvention is shown relative to the manner in which the handle 18 isattached. The handle 18 is attached so that it engages and retains theremovable end cap 14. The handle 18 is fastened onto the outer shell 12of the tube at both ends. In this case, the handle 18 is shown to befastened utilizing snaps 30 although other suitable fastening device arealso acceptable. The handle 18 is also shown to pass through loops 32that are attached to the end cap 14. With the handle strap 18 in thetightest position, as seen in FIG. 1 or 2, it can be seen that thehandle 18 serves also to retain the end cap 14. With the handle in thealternative position, a loop is formed that can be positioned as is seenin either FIG. 3 or 4 to also provide a means for a user to carry thetubular assembly 10. Finally, adjustment means 34 can be provided at theends or near the center of the handle 18 to allow adjustment of thehandle 18 length as desired by the user.

It can therefore be seen that the present invention provides a novelassembly and method of forming a tubular storage assembly 10 that allowsthe use of heavyweight outer shell 12 materials. Further, the presentinvention provides a novel technique for incorporating such heavyweightouter shell 12 materials into useful tubular assemblies 10 at a lowercost and with higher quality results than has been previously known inthe prior art. For these reasons, the instant invention is believed torepresent a significant advancement in the art, which has substantialcommercial merit.

While there is shown and described herein certain specific structureembodying the invention, it will be manifest to those skilled in the artthat various modifications and rearrangements of the parts may be madewithout departing from the spirit and scope of the underlying inventiveconcept and that the same is not limited to the particular forms hereinshown and described except insofar as indicated by the scope of theappended claims.

1. A method of forming a tubular storage assembly comprising: providinga substantially flat sheet of outer shell material; forming said sheetof outer shell material into a predetermined shape having first andsecond opposing edges, said first and second edges configured to havecomplementary mating shapes; providing a two part fastening devicehaving a first half and a second half; attaching the first half of saidfastening device to said first opposing edge; attaching the second halfof said fastening device to said second opposing edge; engaging saidfirst and second halves of said fastening device to retain said firstand second opposing edges in mated relation; and installing a covermember to conceal said fastener and said first and second opposingedges.